Camshaft, Removing And Installing: Installing

Fig 1: Identifying Crankshaft Holder T40069 In Hole, Removal/Installation

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NOTE:

Replace the seals and sealing plugs.

Secure crankshaft -1- in "TDC" position using Crankshaft Locking PinT40069.
The hydraulic adjusting elements and roller rocker lever are inserted.

CAUTION:

Risk of contaminating lubricating system and bearing.

Cover open parts of engine.

Fig 2: Cleaning Sealing Surfaces

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WARNING:

Danger of eye injury.

Wear protective eyewear.

-- Remove any sealant residue on the cylinder head and the guide frame -1- using a rotating plastic brush.

-- Clean any oil or grease off the sealing surfaces.

-- Check the screen -arrow- for dirt; clean it if necessary.

Fig 3: Identifying Screen

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-- Oil running surfaces of both camshafts.

-- Insert the camshafts in the guide frame.

Fig 4: Identifying Compression Ring Ends -1, 2 And 3-

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The placement of the camshafts must be exactly within the axial bearings -arrows- of the guide frame.
The compression ring ends -1, 2 and 3- must face up or down. They must never face sideways.

-- Rotate the guide frame with the camshafts inserted while holding them securely in the frame.

-- Rotate the camshafts until the threaded holes -arrows- face upward.

Fig 5: Identifying Camshaft Threaded Holes

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-- Check if the camshafts still lie in the guide frame axial bearings.

-- Install the Camshaft ClampT40133 in both cylinder heads and tighten -arrows- to 25 Nm.

Fig 6: Identifying Camshaft Adjuster T40133

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NOTE:

Note the expiration date of the sealing compound.

Fig 7: Cutting Tube Nozzle At Front Marking (Nozzle Diameter Approx. 1 Mm)

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-- Cut the tube nozzle at the front marking (nozzle diameter: about 2 mm).

-- Rotate the guide frame again.

Fig 8: Applying Sealant Beads -4 Through 8- To Clean Sealing Surfaces On Guide Frame

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CAUTION:

The lubrication system could be plugged with excess sealant.

Do not apply sealant beads thicker than indicated.

-- Apply sealant beads -4 through 8- to the clean sealing surfaces on the guide frame as shown in the illustration.

Thickness of sealant beads: 2.0 mm.

-- Apply sealant beads -1 through 3- to the clean sealing surfaces on the guide frame as shown in the illustration.

Thickness of sealant beads: 2.5 mm.

NOTE:

The guide frame must be installed within 5 minutes after applying the sealant.

-- Place the guide frame on the cylinder head.

Fig 9: Identifying T40116

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-- Install the Locating Pins T40116 into the guide frame and cylinder head.

-- Tighten the camshaft guide frame bolts, refer to Figure.

Fig 10: Guide Frame Bolt, Tightening Sequence

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NOTE:

After installing the guide frame, let the sealant harden for approximately 30 minutes.

-- Clean the external sealing head holes in the left and right cylinder heads of oil and grease.

Fig 11: Identifying Sealing Plug

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-- Coat the outer circumference of the sealing plug -arrow- with sealant; for the correct sealant .

-- Drive in the sealing plugs until they are flush.

-- Remove the Locating Pins T40116 with the Injector/Combustion Chamber Seal Tool Set - Impact Puller T10133/3.

Fig 12: Removing T40116 Using T10133/3

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Install in reverse order of removal. Note the following:

-- Install the high pressure pump motor housing and the high pressure pump, refer to HIGH PRESSURE PUMP, REMOVING AND INSTALLING .

-- Position the camshaft timing chain on the camshafts, refer to CAMSHAFT TIMING CHAIN, REMOVING FROM CAMSHAFTS .

CAUTION:

Risk of damaging valves and piston heads after working on valve train.

The motor must not be started for about 30 minutes after installing camshafts because the hydraulic equalization elements must seat themselves.
To ensure valves do not strike pistons when starting, carefully rotate engine at least two full revolutions.